Floor panel and method for the manufacture thereof

ABSTRACT

Floor panel of the type comprising a hard top layer forming a decorative surface, from which, together with other identical or similar floor panels, a floor covering can be formed, wherein this floor panel includes at least one sound-absorbing layer which is integrated into the floor panel and is located between other layers of this floor panel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/216,821 filed Aug. 13, 2002, and claims priority to Belgianapplication no. 2001/0547 filed Aug. 14, 2001, the entire contents ofboth of which are incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

A. Field of the Invention

This invention relates to a floor panel and a method for the manufacturethereof.

B. Discussion of Related Art

More particularly, the invention relates to a floor panel of the typecomprising a hard top layer forming a decorative surface, from which,together with other identical or similar floor panels (1), a floorcovering can be formed.

In particular, the invention relates to so-called laminated floorpanels, such as, for example, described in the international patentapplication No. WO 97/47934.

By a floor panel with a hard top layer, any form of panel has to beunderstood which has a hard or relatively hard surface at the side whichis to be walked upon, which feature does not exclude that softermaterials are incorporated in the panel, nor excludes that the panel canshow a certain flexibility.

The floor panels of this type known up to now have the disadvantagethat, when walked upon, they are causing a kind of “clacking” sound. Inparticular the higher tones forming the basis of this sound areexperienced as annoying.

It is known to provide an insulating layer loosely under such floorpanels, either in the form of a foil, or in the form of insulatingpanels, whereby the thus formed insulating layer in particular serves asa thermal insulation, however, simultaneously also has somesound-absorbing effect, in particular in downward direction. However,the sound-absorbing effect of an insulating layer provided under thefloor panels seems to be rather small, in particular if one intends toreduce reflection sounds, more particularly the so-called “footfallsound”.

Also, it is already known to attach an insulating, more particularlythermally insulating, layer in a fixed manner against the underside ofthe floor panels, which of course offers the advantage that such layeris realized under the floor panels simultaneously with the installationof the floor panels themselves, however, moreover to a large extent iscomparable to a separate insulating layer provided beforehand under thefloor panels.

Also, it is already known to provide floor panels with a cork coveringat the upper side, whereby the top surface thereof whether or not isfinished by means of a layer of lacquer, such as transparent varnish orthe like, and whereby it is intended, by installing the floor panels, toform a cork floor. In such embodiment, little sound is produced whenwalking thereon, which is evident, as one will be walking directly onthe relatively soft cork. The disadvantage of such floor panels,however, consists in that the appearance of the decorative surfaceremains limited to the appearance of cork or printed cork, as aconsequence of which the usage possibilities are strongly limited.

The present invention aims at a floor panel of the abovementioned type,in other words, a floor panel comprising a hard top layer forming adecorative surface, which floor panel is realized such that anoptimization or at least a considerable improvement of the soundabsorption is provided, notwithstanding the presence of the hard orrelatively hard surface to be walked on.

SUMMARY OF THE INVENTION

To this aim, the invention relates to a floor panel of the typecomprising a hard top layer forming a decorative surface, from which,together with other identical or similar floor panels (1), a floorcovering can be formed, with as a characteristic that this floor panelcomprises at least one sound-absorbing layer which is integrated intothe floor panel itself and, to this aim, is located between other layersof this floor panel, in other words, is incorporated into the structuralconstruction of the panel and is not simply provided as a coveringagainst the underside of the floor panel.

By integrating one or more sound-absorbing layers into the floor panel,more particularly at a distance above the underside, as well as at adistance below the top surface, it is obtained that, on one hand, suchsoundabsorbing layer, independent from the thickness of the floor panel,can be positioned relatively close to the upper surface, whereas, on theother hand, the global structure of such floor panel still can be keptrelatively thick and stable. Tests have shown that by integrating thesound-absorbing layer, better results are obtained, on one hand, as thethickness of the material situated thereabove, in which the soundsubstantially propagates, is reduced and, on the other hand, in that amultilayer construction is created, which obviously also contributes tothe desired effect in an advantageous manner.

Also, by integrating the sound-absorbing layer into the floor panel, thepossibility is created to keep, at choice at the upper side and/or theunderside of the floor panel, material which can be optimally chosen infunction of the desired purposes, independent from the choice ofmaterial for the sound-absorbing layer.

Preferably, said sound-absorbing layer, viewed according to thethickness of the floor panel, at least extends up into the upper half ofthis panel. Still more particularly, the sound-absorbing layer will beentirely situated in the upper half. Thereby, a relatively thick andconsequently stable basic structure can be maintained under thesound-absorbing layer, whereas the sound-absorbing layer is situatedclose to the top surface, which contributes to an optimum soundabsorption. As a relatively thick basic structure can be maintained, itis not necessary to deviate from standard thicknesses of 1 cm or lessfor the floor panels, and it is even possible to apply the inventionwhile keeping the traditional thicknesses of the floor panels of 7 to 8mm, or even thinner.

Preferably, the sound-absorbing layer, or if there are several thereof,the upper sound-absorbing layer, is situated with its upper side at adistance below the upper side of the floor panel which is smaller than 4mm, and even better is smaller than or equal to 2 mm. As a resultthereof, a particularly good sound absorption is obtained, whereas itstill remains possible to realize a sufficiently solid top surface witha sufficient bearing capacity and impact resistance.

According to another preferred characteristic, the floor panel comprisesonly one sound-absorbing layer integrated between other layers, as aconsequence of which the constructive design of such floor panel remainsrelatively simple. Moreover, thereby it can be achieved that, byrealizing this sole sound-absorbing layer as thin as possible, arelatively large thickness remains which is available for one or morestructural basic layers, for example, basic layers giving globalstrength to the floor panel, such as layers formed of wood-based boardmaterial, more particularly MDF (Medium Density Fiberboard) and/or HDF(High Density Fiberboard).

Preferably, the floor panel, apart from the soundabsorbing layer and thetop layer, then also at least comprises one structural basic layer.Although various structural basic layers can be incorporated into thefloor panel, this latter, according to an important preferred form ofembodiment, will comprise only one structural basic layer, whichcontributes to the constructive simplicity of the whole.

In a particularly preferred form of embodiment, the top layer isattached directly on top of the sound-absorbing layer, more particularlywithout the intermediary of structural basic layers. Therefore, thematerial thickness above the sound-absorbing layer is minimum, whichcontributes to a good sound absorption, as the propagation of sound inthe upper layer is impeded. Still more particularly, it is preferredthat below the structure formed by the sound-absorbing layer with thetop layer directly attached thereon, at least one structural basic layeris present. In this manner, a floor panel with a stable base isobtained, whereby, however, simultaneously a good sound absorption iscreated.

In the most preferred form of embodiment, the construction even is suchthat the floor panel, with the exception of possible adhesive layers orthe like, and with the exception of an insulating layer possiblyprovided at the underside of the floor panel, exclusively consists ofthe structural basic layer, the soundabsorbing layer provided on topthereof, and the top layer provided on top of this sound-absorbinglayer.

According to another form of embodiment of the present invention, atleast one additional layer of material, preferably a structural basiclayer, is present between the sound-absorbing layer and the top layer,which allows that to this aim, a material can be chosen which forms anoptimum sublayer for the applied top layer, for example, which allows tofunction as a support for a decorative layer, when such decorativelayer, for example, is such that it can not be directly attached ontothe applied sound-absorbing material. Such additional layer, which, in apractical embodiment, can consist of wood-based board material, such asparticle board or fiberboard, more particularly MDF and/or HDF, forexample allows to provide the floor panel trouble-free with a decorativetop layer, formed by so-called DPL (Direct Pressure Laminate). With DPL,one or several sheets of material impregnated with resin, amongst whicha printed decorative layer made of paper, are directly compressed ontothe underlying layer, whereby simultaneously heat is supplied, such thatan adherence is obtained automatically. As in the above-saidconstruction, the DPL is pressed upon the HDF, MDF or the like, in otherwords, onto one and the same material surface as in traditional floorpanels, the same adhesive quality and stability can be achieved, withoutthe necessity of special precautions.

The preceding, however, does not prevent the application of a top layeraccording to the DPL principle directly on the sound-absorbing layer,when the material thereof allows this, which may be determined by tests.

According to another form of embodiment of the present invention, thesound-absorbing layer is located between two structural basic layers. Asa consequence, a floor panel is obtained which can be processed and/orcoated in a traditional manner at the upper side as well as at theunderside thereof, for example, can be coated, as aforementioned, byDPL, either preceding to composing the layer structure of which thefloor panels then consist, or after such composing.

As already mentioned in the aforegoing in respect to several forms ofembodiment, it can be stated in general that it is preferred to useboard material consisting of wood or being wood-based for theaforementioned structural basic layers, more particularly pressed plateswhich are formed of wood-comprising material, for example, wood parts,such as chips or fibers, which are mixed with a binding agent.

In particular, for one or more of the structural basic layers, use ismade of plate material formed by MDF and/or HDF. Still moreparticularly, all structural basic layers applied in the floor panelshall consist of MDF and/or HDF.

The use of such wood-based structural basic layers offers the advantageto enable the manufacture of the panels in an economic manner, as wellas the application of traditional processing methods and tools.

Moreover, MDF and HDF, and in general similar fiberboards, too, providea fiber structure with fibers which are substantially situated in ahorizontal plane, which is particularly advantageous for the strength ofthe finished product. As, according to the invention, a sound-absorbinglayer is integrated into the floor panels, the remaining thickness forstructural basic layers mostly is rather restricted. By using boardswith a fiber structure, the fibers of which substantially are situatedin the horizontal plane, the strength, however, remains guaranteed, evenif these structural basic layers have become rather thin.

The floor panel may be provided with one or more backing layers, whichin particular are intended to offer a counterbalance against warping. Ina practical form of embodiment, such backing layer is provided at leastat the underside of the floor panel, in order to offer a balance for thetop layer situated at the upper side of the floor panel.

Also, covering layers and/or backing layers can be incorporated into thefloor panel at other locations, which layers preferably are situated atthe upper side and/or underside of structural basic layers which formpart of the respective floor panel. In this manner, per structural basiclayer a balancing effect can be provided for, without having otherlayers exerting an influence thereupon.

In a preferred form of embodiment, the floor panels are provided withcoupling parts at two or more of their edges. In a simple form ofembodiment, these coupling parts may consist of a traditional tongue andgroove. More particularly, however, use shall be made of coupling partsof the tyke providing for a vertical, as well as horizontal locking, forexample, as described in the international patent application WO97/47934.

Although it is not excluded that such coupling parts, more particularlythe tongue-shaped part thereof, as well as possibly the walls of thegroove-shaped part thereof, are formed entirely out of the material ofthe sound-absorbing layer, it is preferred that these coupling parts areformed at least partially of one or more of said structural basiclayers. This, in fact, offers the advantage that the coupling partsstill have the same qualities in respect to strength, flexibility andthe like, as this is the case with floor panels with a traditionalconstruction.

Regardless whether the coupling parts are manufactured from the materialof a structural basic layer of from another material, it is alwayspreferred that these coupling parts are situated substantially, andpreferably entirely, outside of the sound-absorbing layer or layers, inother words, that these coupling parts and the sound-absorbing material,viewed in the height, are situated at different levels in the floorpanels. This offers the advantage that, when, as described in thefollowing, the sound-absorbing layer or layers are realized in amaterial which offers little strength and/or are realized in a materialwhich is difficult to process, the strength of the coupling parts and/orthe degree of difficulty of forming them is not or only minimallyinfluenced in a disadvantageous manner due to the presence of thesoundabsorbing layer. This latter is in particular valid for embodimentsin which the sound-absorbing layer consists of synthetic material and inwhich the coupling parts are formed by means of a milling process.Milling in the synthetic material indeed may cause problems in respectto cooling, and preferably, the cutting surface through the syntheticmaterial thus will be restricted to a minimum, which, as aforementioned,is possible by situating the coupling parts to be formed outside of thesound-absorbing layer.

More particularly, the sound-absorbing layer or layers are situatedabove the coupling parts. In this manner, such layer can be situatedclose to the upper surface, and therefore the sound insulation remainsmaximum.

The sound-absorbing layer can consist of various materials. Particularlygood results, in respect to absorption as well as in respect toprocessability, are obtained by applying cork or a cork-based material.

Cork also offers the advantage that the final floor panels still areeasy to recycle, such contrary to embodiments in which thesound-absorbing layer consists of synthetic material.

Other advantages of cork are the following:

it is a relatively inexpensive product, as it is a natural product;

B.—cork is waterproof, as a result of which a water repelling effect iscreated, in particular if it is provided above a material layer, such asMDF or HDF, which is sensitive in respect to water;

cork is a product which is easy to process and which offers theadvantage that the applied tools less rapidly show wear and tear than,for example, when processing synthetic material;

cork is relatively easy to glue, as well as easy to print, which allowsthat a number of treatments can be realized without any problem, suchas, for example, the glueing of the cork to the other layers, orprinting the cork when, as will be explained in the following, abevelled part or so-called chamfer, which is provided with a coating orsuch, is realized at the floor panels.

Cork also is particularly recommended for being applied as asound-absorbing layer directly under the top layer, as in this manner agood adherence of the top layer can be guaranteed. Also, vibrations,amongst which sound vibrations, are absorbed almost immediately in thecork.

According to another practical form of embodiment, use will be made of asound-absorbing synthetic material, preferably polyurethane.

According to a particular characteristic, the sound-absorbing layer isformed of a material layer which can be wound up in itself, to whichaim, for example, a thin layer of cork or a thin layer of syntheticmaterial can be applied. Such windable material offers the advantagethat it is easy to utilize in a production process, in particular in acontinuous process, whereby the soundabsorbing layer systematically mustbe provided on and/or between plate-shaped structural basic layers. Thesoundabsorbing material then can be unwound systematically onto theunderlying structural basic layer and can be attached thereto.

In general, it is preferred that the sound-absorbing layer has athickness of less than 2 mm, such in order to keep a relatively largethickness for other layers, for example, for said structural basiclayers. In most applications, moreover a more economical product will beobtained, as the material for forming the structural basic layers, forexample, MDF and/or HDF, mostly is cheaper than the material for thesound-absorbing layer.

Also the thickness of said top layer preferably is limited, moreparticularly to less than 1 mm.

The top layer preferably is realized according to any of the followingpossibilities:

as a laminate layer constructed of material sheets, more particularly aso-called “laminated sheet material;

veneer or the like.

The laminate layer constructed of material sheets may be of differentkind. Preferably, to this aim use will be made of HPL (High PressureLaminate) or the like, which, as known, consists of different layers ofresin or layers formed by supports, such as lengths of paper, which areimpregnated with resin, which layers are compressed to a whole and arecured. Also, so-called formica or the like can be applied. According toanother variant, one may also start from “compact laminate” as a toplayer, which then, instead of being applied as such, is fixed uponunderlying layers, which layers, in accordance with the invention,comprise at least one sound-absorbing layer. Further, also the use ofDPL (Direct Pressure Laminate) or LPL (Low Pressure Laminate) or thelike is not excluded, in any case if the layer situated below the toplayer allows this. The top layer also may be reinforced, for example, bymeans of a reinforcement fleece or such, it may comprise a wear andtear-resistant upper layer, and so on.

In the case that the top layer is fixed directly on top of thesound-absorbing layer, and in particular if this sound-absorbing layeris somewhat compressible, for example, when it consists of cork, it ispreferred that a relatively strong laminate layer constructed in layersis used, such as the aforementioned HPL or formica. The necessarythickness of the top layer to be used therewith can be determinedempirically by means of strength tests, whereby it is tested whether,for example, in function of the thickness of the top layer sufficientimpact resistance, resistance against perforations and such is obtained.

Particularly good results in respect to sound absorption, as well as inrespect to the general composition, are obtained with a structurecomposed of, successively from the bottom to the top, a structural basiclayer formed by a plate-shaped wood-based material, more particularlyMDF/HDF, a sound-absorbing layer formed by cork, and a top layer formedfrom HPL or the like.

According to a particular form of embodiment, the soundabsorbing layerwill be integrated into the top layer, which, of course, is possible indifferent ways. So, for example, this can be realized by taking up aparticularly thin cork layer, when forming the HPL or the like, betweentwo of the material layers of which the HPL is formed.

It is noted that said cork can be applied pure or mixed with othermaterial, for example, as a filling agent present in other materials.

Finally, the invention also relates to a method for manufacturing afloor panel, more particularly a floor panel with an integratedsound-absorbing layer. To this end, it provides for a method, wherebyfirst, composed plates of a larger size are manufactured, from whichsubsequently each time several floor panels are formed, characterized inthat said plates are manufactured at least by supplying one or moreboard-shaped structural basic layers, supplying material, wound up inrolls, for forming said sound-absorbing layer, and unwinding thismaterial from those rolls, as well as supplying the top layer or thematerial for forming such top layer, whereby the respective composedlayers are provided on top of each other.

As, according to this method, use is made of a windable sound-absorbingmaterial, this latter is easy to handle in a production process, asthen, the sound-absorbing material easily can be unwound andsubsequently be attached upon the plate-shaped structural basic layers.Also, it possibly may be directly fixed upon such basic layer by rollingit thereon, by the intermediary of an adhesive agent, adhesive layer orthe like.

A. It is clear that the different layers of the floor panels of theinvention can be attached to each other in any manner. This may beperformed, for example, by means of appropriate kinds of-glue or otheradhesive materials, by having certain layers cure on top of each otheror by fixing them upon each other by melting, or by providing thindouble sided adhesive layers in between them.

When mentioning a “direct” attachment of the top layer on an underlyinglayer, this does not exclude that thin layers are present in between, bywhich then, for example, adhesive layers, fleeces, foils and the likeare intended which do not have a considerable thickness.

It is clear that floor panels in which materials in the form of anintegrated layer are applied, providing for a distinct sound-absorbingeffect, even if those materials are integrated into such floor panel inthe first place for other purposes, also are within the scope of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

With the intention of better showing the characteristics of theinvention, hereafter, as an example without any limitative character,several preferred forms of embodiment are described, with reference tothe accompanying drawings, wherein:

A. FIG. 1 represents a floor panel according to the invention;

B. FIG. 2 represents a cross-section according to line I-II in FIG. 1;

C. FIG. 3 represents another embodiment of the floor panel according tothe invention;

D. FIG. 4, at a larger scale, represents a possible embodiment of thepart indicated by F4 in FIG. 3;

E. FIGS. 5 to 8 represent views analogous to that of FIG. 4, however,for four variants;

F. FIG. 9 in cross-section represents a part of another variant.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

As represented in FIGS. 1 and 2, the invention relates to a floor panel1 which is provided with a ‘hard or relatively hard top layer 3 at theupper side 2.

As schematically represented in FIG. 2, this floor panel 1 according tothe invention comprises at least one sound-absorbing layer 4 which isintegrated into the floor panel 1 itself, in other words, isincorporated into the structure of the floor panel 1.

Viewed according to the thickness T of the floor panel 1, asrepresented, the sound-absorbing layer 4 thus is situated at a distanceD1 above the underside 5 of the floor panel 1, as well as at a distanceD2 below the upper side 2.

As explained in the introduction, the distance D2 preferably is as smallas possible, and in a practical application, this distance thus will besmaller than 4 mm, or even better, will be smaller than or equal to 2mm.

As represented in FIG. 2, the floor panel 1, in a known manner, can beprovided with coupling parts 10-11 at two or more of its edges, 6-7and/or 8-9, respectively, which coupling parts in this case consist of aclassical tongue and groove.

Of course, other forms of coupling parts 10-11 can be applied, forexample, of the type which, as represented in FIG. 3, in coupledcondition provides for a mechanical locking, in vertical as well as inhorizontal directions, whereby the coupling, for example, is performedby shifting the floor panels 1 in mutual respect towards each other, asillustrated at the left hand side of FIG. 3, and/or by turning them intoeach other, as illustrated at the right hand side of FIG. 3.

FIGS. 2 and 3 show that, when the floor panels 1 are equipped with suchcoupling parts 10-11, the sound-absorbing layer 4 preferably is situatedoutside of these coupling parts 10-11, with which it is meant that thislayer 4 is not situated at the level of the tongue-shaped andgroove-shaped parts formed by these coupling parts 10-11. In thismanner, it is guaranteed that the sound-absorbing layer 4, in theproximity of the edges 6-7 and/or 8-9 provided with coupling parts10-11, during the formation of the profile of these edges, is cutthrough exclusively vertical or substantially vertical. Hereby, theadvantage is obtained that, as explained in the introduction, thestrength of the coupling parts 10-11, and in particular the strength ofthe tongue-shaped parts, is not disadvantageously affected by thepresence of the material of the sound-absorbing layer 4. Also, thedistance over which the applied machinery tools must cut through thematerial of the sound-absorbing layer 4, thereby is restricted to aminimum.

As further represented in FIGS. 2 and 3, the sound-absorbing layer 4preferably is situated above the coupling parts 10-11. This isparticularly important in the embodiment of FIG. 3, in other words,where coupling parts 10-11 are applied whereby the mechanical locking inhorizontal direction is obtained by means of locking parts 12-13, at theunderside of the tongue-shaped coupling part 10 and the upper side ofthe lip 14 situated at the underside of the groove-shaped coupling part11, respectively. As the sound-absorbing layer 4 is situated above thecoupling parts 10-11, it is impossible that the strength of thelowermost part of the floor panel 1, and thus also of the lip 14 whichmust be sufficiently strong in order to allow such locking, isdisadvantageously affected by the presence of the sound-absorbing layer4, regardless of the strength of the material of which the layer 4 ismanufactured.

Apart from the sound-absorbing layer 4, the floor panels 1 can beconstructed from several layers in different manners. In considerationof the fact that this construction may differ, in FIGS. 2 and 3 thefloor panels 1 thus are represented only schematically. This, however,does not exclude that certain compositions are preferred, for example,the compositions as described in the following by means of FIGS. 4 to 9.

In FIG. 4, a particularly important form of embodiment of the inventionis represented, whereby the top layer 3 is provided directly on thesound-absorbing layer 4 integrated in the floor panel 1, without thepresence of a structural material layer in between. Thereby, thedistance D2 is reduced to a strict minimum, to wit to the thickness orapproximately the thickness of the top layer 3, with the advantage thatthe propagation of soundwaves is rendered particularly difficult.

In the example of FIG. 4, one structural basic layer 15 is providedbelow the sound-absorbing layer 4. Further, at the underside of thisbasic layer 15, a backing layer 16 is provided, which, on one hand,forms a protection, however, on the other hand, also is intended tocreate a balancing effect in respect to the top layer 3. Moreparticularly, the purpose of the backing layer 16 is to counteract thepossible warping of the floor panels 1 as a result of forces occurringbetween the top layer 3 and the respective layer upon which this toplayer 3 is provided.

However, it is clear that the construction below the sound-absorbinglayer 4 also can be of another kind.

In a practical form of embodiment of the example of FIG. 4, the basiclayer 15 consists of a board based upon a wood product, moreparticularly a composed wood product, such as fiberboard, preferably MDF(Medium Density Fiberboard) or HDF (High Density Fiberboard), whereasthe sound-absorbing layer 4 consists of cork. In this form ofembodiment, the top layer 3 preferably consists of a so-called“laminated sheet material”, more particularly HPL (High PressureLaminate), the thickness of which is chosen such that a sufficientlystrong support surface at the upper side of the floor panel 1 isobtained. This thickness can be empirically determined and possibly alsocan be chosen in function of the hardness of the sound-absorbing layer4.

The backing layer 16 can be constructed in a similar manner as the toplayer 3, however, with the difference that a decorative surface isformed at the top layer 3, for example, in that in the layer structureof the top layer 3, a printed decorative layer is provided, whereas thisis not necessary at the backing layer 16. The decorative surface at thetop layer 3 can be of different kind and, for example, may comprise anillustration forming an imitation of parquetry or wood.

Preferably, the different layers are provided on top of each other bymeans of an appropriate adhesive, to which end, for example, adhesivescan be used which usually are applied for attaching HPL and the likeupon a sublayer.

FIG. 4 only is a schematic representation, and of course, the relationsbetween the thicknesses of the different layers can be chosen different.In a practical application, the basic layer 15, for example, will have athickness of approximately 5 mm, whereas the sound-absorbing layer 4 hasa thickness of 2 mm and the top layer 3 has a thickness of 1 mm. Ofcourse, according to different variants, values can be applied whichtotally deviate from the abovesaid.

FIG. 5 shows a part of a floor panel 1 with a construction which can becompared to that of the floor panel 1 of FIG. 4, with the soledifference that an additional covering layer 18 is provided between thesound-absorbing layer 4 and the basic layer 15, on the upper side of thebasic layer 15. Of course, this layer construction, too, can be realizedin different manners. One possibility consists, for example, in thatfirst the basic layer 15 is provided with the covering layer 17 and thebacking layer 16, by means of classic DPL techniques (Direct PressureLaminate), after which, by means of adhesives, the sound-absorbing layer4 and the top layer 3 are attached thereupon.

According to FIGS. 6 and 7, the floor panels 1, apart from thesound-absorbing layer 4, substantially comprise two structural basiclayers, more particularly the represented layers 18 and 19, which aresituated above and below the sound-absorbing layer 4. At least one, andpreferably both, of these basic layers 18 and 19 preferably consist ofwood or a wood-based material, more particularly MDF and/or HDF.

The embodiments of the FIGS. 6 and 7 offer the advantage that theoutermost layers, in other words, the top layer 3 and the backing layer16, do not have to be fixed directly on the sound-absorbing layer 4, asa result of which, on one hand, the material of the sound-absorbinglayer 4 can be chosen in an optimum manner in function of the intendedsound absorption, whereas the materials of the basic layers 18 and 19can be chosen optimally in respect to the technique which preferablywill be used for adhering the top layer 3 and the backing layer 16 tothe basic layers 18 and 19.

The form of embodiment of FIG. 7 further differs from that of FIG. 6 inthat at the underside of the basic layer 18, a backing layer 20 isprovided, whereas at the upper side of the basic layer 19, a coveringlayer 21 is provided. In such case, for example, it is perfectlypossible to realize all the layers 3-16-20-21 as DPL, whereas the basiclayers 18 and 19 consist of wood-based plate material, more particularlyMDF or HDF.

In general, it is clear that the application of covering layers and/orbacking layers in particular is favourable in combination withstructural basic layers consisting of materials traditionally appliedfor laminated floors, whereby in first instance thus MDF and/or HDF areintended. However, the use of such covering layers and/or backing layersis not always necessary.

FIG. 8 shows a part of a floor panel 1 with a similar structure as thatfrom FIG. 4, however, with the difference that at the underside of thefloor panel 1, an additional layer 22 is provided which is formed by acompressible material, whether or not with thermal or sound-insulatingfeatures, which offers the advantages that during installation,unevenness are leveled. This layer 22 consists, for example, ofsynthetic foam.

In FIG. 9, another variant is represented whereby the floor panel 1, atone or more of its upper edges 23, is provided with a bevelled part 24or the like, more particularly a so-called chamfer, whereby the bevelledpart at least partially extends through the soundabsorbing layer 4. Inorder to prevent that the layer structure becomes visible in an annoyingmanner, a decorative covering 25 is provided on the bevelled part. Thecovering 25 consists, for example, of a print obtained by means oftransfer print, for example, as described in the international patentapplication PCT/BEO1/00008, or another printing technique. Also, acovering strip, lacquer or the like can be provided on the bevelledpart.

According to a not-represented variant to the embodiment of FIG. 9, thethickness of the layer 4 is chosen such that the bevelled part 24exclusively extends through the top layer 3 and the sound-absorbinglayer 4 and not through the lower-situated layer or layers. This offersthe advantage that the sound-absorbing layer 4, in any case if thelatter is water-repellent, for example, consists of synthetic materialor cork, also at the location of the bevelled part 24 forms a totalprotection against moisture penetration from the upper side towards theunderlying layers, for example, the basic layer 15.

In combination with such bevelled part 24, preferably cork will be usedfor the sound-absorbing layer 4, as this can easily be printed on by,for example, said transfer printing.

Of course, such bevelled part 24 also can be applied in all other formsof embodiment.

Although in the figures only embodiments with one soundabsorbing layer 4are represented, it is clear that according to variants, also severalsound-absorbing layers 4 can be integrated in such floor panel 1. Alsothe structural basic layers 15-18-19 in their turn can be composed ofseveral layers, whether or not provided with more or less coveringlayers or backing layers.

The mutual attachments of the different layers can be realized, asaforementioned, in any manner.

According to a particular technique, one or more layers can be appliedwhich will melt by heating them at their upper surface and which, bysubsequently bringing them together with other layers, can be adhered tothese latter.

The sound-absorbing material can be of different kind. In general,hereby a material has to be understood which shows considerably bettersound-absorbing qualities than the structural basic layers, such as MDFand HDF, which traditionally are applied in such floor panels.

Although the layer situated below the sound-absorbing layer 4 preferablyis a structural basic layer, and consequently mostly consists of a layerwhich does not show any particular sound-absorbing characteristics, itis not excluded to provide, according to a variant, a sound-absorbinglayer, whether or not consisting of the same material, under thesound-absorbing layer 4 integrated according to the invention, forexample, instead of a structural basic layer.

The present invention is in no way limited to the forms of embodimentdescribed as an example and represented in the figures, on the contrary,such floor panels, as well as the aforementioned method, can be realizedaccording to different variants, without leaving the scope of theinvention.

1. Floor panel from which, together with other identical or similarfloor panels, a floor covering can be formed, said floor panelcomprising layers including a top layer forming a decorative surface anda panel top side, and at least one sound-absorbing layer which isintegrated into the floor panel and is located between other layers ofthe floor panel; wherein apart from the sound absorbing layer and thetop layer, at least a first structural basic layer comprising a materialselected from the group consisting of MDF and HDF is provided; whereinthe sound absorbing layer is a compressible, vibration absorbingmaterial; wherein said first structural basic layer is situated belowthe sound-absorbing layer, such that the sound-absorbing layer islocated between said top layer and said first structural basic layer;wherein the panel along at least two of its edges includes mechanicalcoupling parts enabling vertical as well as horizontal locking betweencoupled similar panels, said coupling parts being formed integrally inone piece with said first structural basic layer; wherein said firststructural basic layer has a higher strength and is less compressiblethan the sound-absorbing layer.
 2. Floor panel according to claim 1,wherein said sound-absorbing layer, viewed in cross-section of the floorpanel, is disposed at least partially in the upper half of the floorpanel.
 3. Floor panel according to claim 1, wherein said sound-absorbinglayer, viewed in cross-section of the floor panel, is disposed entirelyin the upper half.
 4. Floor panel according to claim 1, wherein thesound-absorbing layer, viewed in cross-section of the floor panel, isdisposed at a distance (D2) below the upper side of the floor panel lessthan or equal to 2 mm.
 5. Floor panel according to claim 1, wherein onlyone sound absorbing layer is integrated between other layers of thepanel.
 6. Floor panel according to claim 1, wherein said firststructural basic layer is a sole one-piece structural basic layer. 7.Floor panel according to claim 1, wherein the top layer is fixeddirectly on top of the sound-absorbing layer, without intermediatestructural basic layers.
 8. Floor panel according to claim 1, whereinthe sound-absorbing layer is provided on top of said first structuralbasic layer, and the top layer is provided on top of thissound-absorbing layer, exclusive of any adhesive layers and insulatinglayer on the panel underside.
 9. Floor panel according to claim 1,including at least one backing layer.
 10. Floor panel according to claim9, wherein the backing layer is provided at least at the underside ofthe floor panel.
 11. Floor panel according to claim 1, wherein said atleast one sound-absorbing layer is situated outside of the couplingparts.
 12. Floor panel according to claim 1, wherein the sound-absorbinglayer comprises a sound-absorbing synthetic material.
 13. Floor panelaccording to claim 1, wherein the sound-absorbing layer is formed of amaterial layer which can be wound upon itself.
 14. Floor panel accordingto claim 1, wherein the sound-absorbing layer has a thickness of lessthan 2 mm.
 15. Floor panel according to claim 1, wherein the top layerhas a thickness of less than 1 mm.
 16. Floor panel according to claim 1,wherein the sound-absorbing layer is integrated into the top layer. 17.Floor panel according to claim 1, including a bevel-like part at anupper edge, wherein the bevel-like part at least partially extendsthrough the sound-absorbing layer; and wherein on this bevel-like part,a decorative covering is printed.
 18. Floor panel according to claim 1,including a layer of a compressible material located against theunderside of the floor panel.
 19. A floor panel from which, togetherwith other identical or similar floor panels, a floor covering can beformed, said floor panel comprising: a plurality of layers including atop layer forming a decorative surface and a panel top side, and atleast one sound-absorbing layer integrated into the floor panel andlocated between other layers of the floor panel; wherein said decorativesurface is formed at the top layer in that a printed decorative layer isprovided in a layered structure of the top layer; and wherein said toplayer is provided directly on said sound-absorbing layer or wherein saidsound-absorbing layer is integrated in said top layer; wherein apartfrom the sound absorbing layer and the top layer, at least a first basiclayer comprising the same material as said sound absorbing layer isprovided; wherein the sound absorbing layer is a compressible, vibrationabsorbing synthetic material; wherein said first basic layer is situatedbelow the sound-absorbing layer, such that the sound-absorbing layer islocated between the decorative layer and said first basic layer; whereinthe panel along at least two of its edges includes mechanical couplingparts enabling vertical as well as horizontal locking between coupledsimilar panels.
 20. The floor panel of claim 19, wherein the top layerfurther includes a reinforcement fleece.
 21. The floor panel of claim19, wherein the first basic layer provides strength to the floor panel.22. The floor panel of claim 19, wherein the floor panel, with theexception of adhesive layers, exclusively consists of said top layer,said sound-absorbing layer and said first basic layer.
 23. The floorpanel of claim 19, wherein the floor panel, with the exception ofadhesive layers, exclusively consists of said top layer, saidsound-absorbing layer, said first basic layer and an insulating layerprovided at the underside of said floor panel.
 24. The floor panel ofclaim 23, wherein said insulating layer comprises synthetic foam. 25.The floor panel of claim 19, wherein said coupling parts are at leastpartially formed from said first basic layer.
 26. The floor panel ofclaim 19, wherein said top layer, said sound-absorbing layer and saidbasic layer are fixed upon each other by melting.